In order to improve the load-bearing performance of the NGW-L112-71 planetary reducer base, optimization can be carried out around the four core directions Combined with the actual stress conditions of the base, including rated torque, impact vibration and installation form, a landing improvement plan is formulated. The specific implementation steps are as follows:of structural deformation resistance, material failure prevention, connection loosening prevention, and working condition load reduction .
1. Preliminary investigation: find out the root cause of insufficient bearing capacity of the base
Before optimization and transformation, the root cause of the fault must be located first to avoid invalid modifications, which mainly rely on load calculation and structural inspection.
Confirm on-site load parameters
Refer to the equipment manual and on-site working conditions to sort out various load data of the NGW-L112-71 reducer: Static load: The weight of the reducer is about 35~50kg, plus the weight of the motor, driven equipment and other ancillary components, as well as the static pressure borne by the base itself; Dynamic load: The output rated torque range is about 800~1800N·m (subject to the product sample). Impact torque will be generated during the start and stop stages of the equipment, generally up to 2~3 of the rated torque. times; at the same time, there are also cyclic stress loads caused by continuous alternating vibration.
Check for base weak points
Diagnosis is completed using visual inspection and finite element simulation analysis: Visual inspection: Focus on checking whether cracks appear around the bolt holes and corners; observe whether there are any depressions in the installation plane and whether subsidence deformation occurs in the cantilever part; Simulation analysis: Use ANSYS, SolidWorks and other simulation software to establish a model to simulate the stress distribution under rated load conditions. Focus on monitoring the stress concentration phenomenon near the bolt holes, the intersection between the stiffener plate and the body, as well as areas with insufficient stiffness such as smooth bottom plates and cantilever sections.
2. Four major optimization measures to comprehensively improve the bearing capacity of the base
1. Structural optimization to improve the base’s resistance to deformation and reduce stress concentration
Structural design is the basis of load-bearing capacity. Special reinforcements are made for weak areas discovered through simulation and inspection. Different defects correspond to different reconstruction plans.
2. Material upgrade to improve base strength and fatigue resistance
The material itself determines the upper limit of the base"s load capacity. It is necessary to select the appropriate base material according to the load type and match the corresponding processing technology.
Note: After material replacement, the process must be matched simultaneously. For example, if 40Cr material is selected, quenching and tempering (quenching + high temperature tempering) must be performed to control the hardness HB220-250; if Q460 steel plate is used for welding, the welding rod should be E50 series. After welding is completed, a stress relief annealing treatment of 600~650°C for 2 hours is performed to prevent weld cracking.
3. The connection structure is strengthened to ensure rigid force transmission between the reducer, base and frame.
The connection position is often the shortcoming of the entire load-bearing system. Strengthen the three connection nodes to prevent the problem of the base body being intact but the connection part failing first.
① Connection between reducer and base
Bolt upgrade: replace conventional GB/T 5782 grade 4.8 ordinary bolts with GB/T 1228 grade 8.8 high-strength bolts, with a tensile strength of ≥800MPa; enlarge the bolt specifications as needed, such as replacing M12 with M16, and increase the number of bolts from 4 to 6~8, using a symmetrical arrangement. Anti-loosening and bonding treatment: Use spring washers + double nuts to inhibit loosening due to vibration, or apply Loctite 243 thread locking glue; clean the oil stains and burrs on the joint surface of the reducer and the base, and add copper gaskets if necessary to improve surface bonding accuracy.
② Connection between the base and the frame/basic ground
Anchor bolt reinforcement: GB/T 799 8.8 grade anchor bolts are used for ground fixing scenarios and are locked with double nuts; the bolt holes are filled with epoxy resin mortar, and after solidification, the connection rigidity is improved and the bolts are inhibited from loosening.
